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Cutting Reminders

  • Jig is being designed to act as a stencil to allow proper cutting of headlight (will be able to stand on its own)

  • Undercutting is fine, not super problematic, can be sanded to perfection though tedious

  • Overcutting is very problematic if headlight cutout is too big as filling in the gap can lead to aerodynamic flaws in aerobody

  • Kerf needs to be considered when making design of headlight and cutting

  • The space created by kerf can be used to help keep up the headlight for integration (originally thought of tape but requires re-consideration

Cutting Techniques

  • Abrasive Waterjet supersonic erosion can cut through all composites (learned that there’s no hand held waterjet cutter so no waterjet)

  • Laser cutting is an option as well but same problem as waterjet arises of portability

  • For Carbon Fiber, the laser requires to be a CO2 or fiber laser

    • Best performance with hybrid laser of] 10.6 micron CO2 and 1.06 micron fiber wavelength mix

  • Another problem with both laser and waterjet is that it is for 2D cutouts, same thing with CNC mill

Carbon Fiber

Rotary Techniques

  • Dremel (Method of choice) with tungsten carbide or diamond bits (bits and blades are going to be checked to see what’s installed or available)

  • Saws (jigsaw, bandsaw, scroll saw, table saw, etc.)

    • For jigsaw, it’s an option but creates a lot of dust which needs caution when handling. Vacuum can help control dust levels

    • Fine-tooth carbide blade would be used

  • Abrasive cutting saws can be used as attachments

Hand Held Techniques

  • Saws (Hacksaw, coping saw)

Increased TPI is better and thinner blade for sharper cuts

Angle Grinders

  • Better than rotary but requires caution when using

  • Abrasive cutting saw

https://www.elevatedmaterials.com/best-methods-for-cutting-carbon/

Kevlar

  • Diamond wheel blade is optimal

  • Tungsten carbide is an option but not as nice as diamond

  • Kevlar is difficult to cut due to polymer chains

  • Waterjet works on Kevlar but if there’s no hand held cutter we’re screwed!!

Dremel (more in-depth)

  • Solid carbide or diamond grit for cutting composites

Integration

  • Found out that integrating headlights is top secret and trade secret so no info on that

  • Keep headlight up through attachment to aerobody itself

    • idea for bolting to chassis was put aside as chassis is too far away from aerobody especially at the back

  • Headlight need to be flush with aerobody to maintain aerodynamics

  • Some ideas we came up with in meeting:

    • Tacky tape around headlight to keep it in place and stop air to pocket or flow, less drag that way

    • Regular tape was used in MS14 to keep it up

  • This ideas kind of got put aside for re-consideration as the light can heat up to very high temperatures (80 degrees) so the tape melting or deforming is highly possible making tape of any sort unfeasible

  • More ideas are welcomed!!!!!!!!

Manufacturing

  • Thermoforming of windshield is difficult (thinking of getting a company to do it for us for free just need to provide MDF and Mold)

  • Jig will be 3D printed

  • Thermoforming of headlight will be done in house just make sure to keep size small enough for it to fit in our machine

  • Mold will be done with wood for head/tail light I believe (correct me if I’m wrong)

  • Polycarbonate is used for windshield for REGS purposes